WO2016068822A1

WO2016068822A1 - Self consolidating lightweight mortar brick

Info

Publication number: WO2016068822A1
Application number: PCT/TR2015/050149
Authority: WO
Inventors: Kasim MERMERDAS
Original assignee: Hasan Kalyoncu Üniversitesi
Priority date: 2014-10-27
Filing date: 2015-10-23
Publication date: 2016-05-06

Abstract

This invention is related to manufacture of bricks wherein after applying five several processes to fly ashes which is the waste of thermal power plants is used in the mortar brick production of whom strength value is 5-10 times more than and more resistant to earthquake than present bricks. New product will provide 10 important contribution to the heat and sound isolation of the buildings due to the high gap rate of lightweight aggregates, besides of the valuation of the fly ashes which is the waste of thermal power plants.

Description

Title of Invention : [SELF CONSOLIDATING LIGHTWEIGHT

MORTAR BRICK]

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Technical Field

[0002] This patent application covers the production of high performance lightweight bricks (LWB) made of self-consolidating mortar.

Background Art

[0003] Being one of the most commonly used materials in construction industry, brick is required to carry the sustained load as well as having proper heat and sound insulation. Therefore, the studies done on this issue generally focus on the reduction of the self-weight. In this invention, the production procedure for LWB with improved insulation properties and high mechanical properties leading the enhanced seismic performance of the partition wall is aimed to be specified. In the production of the LWB self-consolidating mortars containing lightweight pellets produced from waste materials will be used.

[0004] As a result of storing and disposal problems, fly ash which is a byproduct obtained from thermal power plants is a harmful material for environment due to contamination of air and water. Annual fly ash production in Turkey is above 15 million tons while it reaches to 400 million tones all over the World. Although, there is such a huge amount of production only a limited fraction of this amount is utilized in construction sector. This invention may lead a new field of beneficiation of fly ash and hence reduction in the amount deposited.

[0005] TR2013/00351 numbered patent application is related to lightweight brick which was made by creating a foam filled gaps. The purpose of the invention is to provide mix design procedure for the ingredients which are Portland cement, magnesium oxide, water-soluble solid magnesium sulphate heptahydrate, fly ash, calcite, pumice, sodium carbonate, acrylic, resin, polymer, etc. and several chemicals affecting setting time and foam agent. The patented invention will provide the decrease in the own weight of the building and ease in the construction of the wall.

[0006] In the TR201 1 /04725 numbered patent application; utilization of foam in the production of lightweight brick, block wall panels, prefabricated reinforced concrete wall element, cement finish on slabs, ceramic, fiber reinforced facade elements, fiber-reinforced concrete wall panels behind the filler, heat insulation in the masonry buildings were mentioned. The foam chemicals mentioned in the application was composed of soapwort root surcharge, black tea, pomegranate molasses, molasses, resin polymer, and ethyl alcohol.

Summary of Invention

[0007] The purpose of the invention is to propose a new type of high performance brick which is made of a mortar including artificial lightweight aggregates manufactured from fly ash obtained as a waste material from thermal power plants. Since this type of brick reduces the self-weight of the building and it has 5 to 10 times higher strength than conventional brick, the seismic performance of the building is supposed to be improved. Moreover, as result of increased void ratio due to the artificial aggregates used in the production, the insulation properties will be improved. Considering the large consumption of fly ash, the product will be classified as environmentally friendly low cost construction material.

Brief Description of Drawings

[0008] Size and images of bricks manufactured from material of lightweight aggregates pellets manufactured from fly ashes outgoing from thermal power plants and other raw materials is shown in the figures.

Fig.1

[0009] [Fig.1 ] illustrates dimensions of bricks 190x1 90x135 mm and 190x190x85 mm Fig.2

[0010] [Fig.2] illustrates steam curing process which applied to LWBs

Detailed Description of the Invention

[001 1 ] Lightweight aggregates manufactured by cold bonding pelletization of fly ash are exposed to sintering process and then the sintered aggregates are screened from the sieves having 4 mm opening size. The materials shown in Table 1 are mixed according to the proportions given in Table 2. The produced mortar is expected to satisfy minimum mini-slump flow diameter of 25 cm and the plastic viscosity of 10-15 Pa.s. This conditions provide that the fresh mix is self- compacting mortar. Therefore, consolidation of the mortar in molds without external compaction process can easily be satisfied.

[0012] The aforementioned mix is poured into a proper mold to have a brick with the geometrical properties and vertical voids given in Figure 1 .

[0013] Just after the fresh mix is poured into the molds, they are transferred to the chambers which has 70±2 °C temperature and 90±5% relative humidity. The steam treatment shown cycle shown in Figure 2 is applied. At the end of the cycle (23±1 hours later) the bricks are taken out of the molds and they become ready for usage.

[Table 1]

Class F fly ash. Fineness value must be

Fly ash between 300-450 m²/kg. The specific gravity is between 2.0-2.20

The limestone powder or marble powder which can pass 0.125 mm sieve. The

Filler material specific gravity is between 2.60-2.75, specific surface area (fineness) is between 350-600 m²/kg.

Sintered lightweight aggregate. Dry powder mix is 90% fly ash 10% CEM I 42.5R cement. After manufactured by

Lightweight aggregate pellets peptization process the pellets are transferred to sintering process at 1200 °C. The specific gravity of the sintered pellets is between 1 .20 and 1 .50

Polycarboxilic ether type high range

Chemical admixture water reducing admixture. The specific gravity is between 1 .00-1 .10

The properties of the material to be used for production of lightweight mortars

[0014] [Table 2]

The mix proportions offered for production of self compacting lightweight mortars (kg/m³) Industrial Applicability

[0015] Consumption of high volumes of fly ash provides the production of an environmental-friendly material.

[0016] Although having less weight than the conventional bricks in the industry about 5 to 10 times higher strength is obtained. This provides an enhancement in the seismic behavior of the buildings.

[0017] Since the void ratio in the lightweight aggregate pellets used in the production is very high (about 7-10%) the insulation properties of LWB is far better than conventional ones.

Claims

[Claim 1 ] [The invention (LWB) has higher strength than the available conventional bricks and it is characterized by it is manufactured from mainly fly ash pellets and fly ash as a binding material together with cement.

[Claim 2] The production steps for LWB in Claim 1 are cold bonded fly ash pellets are exposed to sintering process and screened from 4 mm sieve, preparation of the fresh mortar mix according to the materials given in Table 1 and mix proportions given in Table 2, the freash mix must have minimum mini slump flow diameter of 25 cm and plastic viscosity of 10-15 Pa.s, The prepared fresh mix must be poured into proper molds to have bricks of the desired shape.

[Claim 3] After the mix is prepared and poured into the molds as specified in Claim 2 they are transferred to the chamber with 70±2 °C temperature and relative humidity of 90±5%. The fresh mix of LWB is exposed to the stream curing treatment according to the cycle specified in Figure 2, after 24 hours of the cycle the specimens are demolded and becomes ready for usage.